Method for freezing and drying liquids and semisolids



T. R. FOLSOM Nov. '4, 1952 METHOD FOR FREEZING AND DRYING LIQUIDS AND SEMISOLIDS 6 Sheets-Sheet 1 Original Filed Aug. 2, 1941 INVENTOR. I A. FOZJOM drroFA/U Nov. 4, 1952 T. R. FOLSOM 2,616,604

METHOD FOR FREEZING AND DRYING LIQUIDS AND SEMISOLIDS Original Filed Aug. 2, 1941 6 Sheets-Sheet 2 INVENTOR. I R F01 50M A Woe/v5 r T. R. FOLSOM Nov. 4, 1952 METHOD FOR FREEZING AND DRYING LIQUIDS AND SEMISOLIDS 6 Sheets-Sheet 3 Original Filed Aug. 2, 1941 co a n INVENTOR. r I? Fol $0M A rmmvsr T. R. FOLSOM Nov. 4, 1952 METHOD FOR FREEZING AND DRYING LIQUIDS AND SEMISOLIDS 6 Sheets-Sheet 4 Original Filed Aug. 2, 1941 INVENTOR. 77 A. Fol 50M ATTORNEY Nov. 4, 1952 T. R. FOLSOM METHOD FOR FREEZING AND DRYING LIQUIDS AND SEMISOLIDS Original Filed Aug. 2, 1941 6 Sheets-Sheet 5 INVENTOR. 73' R. F01 $0M A TTORNE) Nov. 4, 1952 T. R. FOLSOM ,6

METHOD FOR FREEZING AND DRYING LIQUIDS AND SEMISOLIDS Original Filed Aug. 2, 1941 6 Sheets-Sheet 6 INVENTOR. I A. FOZJOM Patented Nov. 4, 1952 METHOD FOR FREEZING AND DRYING LIQUIDS AND SEMISOLIDS Theodore R. Folsom, San Diego,'Calif.

Original application May 2, 1941, Serial No.

391,561, now Patent No. 2,411,152, dated November 19, 1946. Divided and this application August 22, 1946, Serial No. 692,319

4 Claims.

This invention relates to methods for removing volatile components (such as water) from a "liquid or semi-solid product at low temperature, and more particularly to improved methods which make partial use of vacuum sublimation to .remove at least .a part of the volatile components present.

The present application is a division of my prior application Serial No. 391,561 filed May 2, 1941, .now Patent No. 2,411,152, Nov. 19, 1946.

Theinvention aims to provide a more eifective method of and apparatus for removing part or all of the volatile components of delicate substances which will not tolerate high temperatures, asfor example, biological products such as serum and plasma, .as well as other liquids and semisolids. .More particularly, the improvements permit more rapid removal of the volatile components of such products, permit the production of a superior and more useful final prodnot, and further permit the drying process to be more effectively carried out in a continuous or a semi-continuous manner under sterile conditions.

Older methods'forremoving water from a productinthefrozen state are extremely slow, as well asfawkwardand inefli'cient. The present invention permits products to be dessicated from the frozen state rapidly, efficiently, and conveniently, in 'a continuousmahner, either in small quantities or in extremely large quantities.

.The'invention also'provides a more effective,

rapid, "and convenient means for converting a liquid or semi-solid into a suitable frozen state for further processing while in the frozen state.

Older methods devised to dessicate biological. products'atlow temperature have several physical limitations which the present invention overcomes. The Outstanding limitation of the older methods is the lack of convenient speed and capacity when very low temperatures, especially those below the freezing temperature of the prodnot, are maintained. It has been known that it is advantageous to remove at least the last traces of water from the product while the latter is maintained in the frozen state. It has also been known that the final product is more soluble when the product is kept frozen while the last traces of water are removed. However, experience has shown that vacuum sublimation carried out in the older manner is awkward and slow.

2 conventionally, the product is frozen in large masses andthen exposed in a vacuum, and the vapor is removed by a pumping system.

The methodof exposing large masses of frozen substance to vacuum for the purpose of removal of volatileshasthree main disadvantages or limitations: (1) 'The sublimation process is very slow because heat of sublimation cannot readily and safely be madeavailable. (2) Thelarge massof .ice dries intobulky slabs or chunks not easily handled .or transferredinto more suitable final containers. (.3) The whole process is not only slow but'cannot readily be carried out in a direct and continuous manner from the original liquid or semi-solid product to the final packaged dried product. A more detailed discussion of these three limitations follows:

(1) A great deal of heat energy is required to convert a volatile product which is in the frozen state, into a vapor state. The older methods failed to supply this heat rapidly while maintaim ing the frozen condition of the product. When frozen in a large slab, and exposed to a vacuum, the product generally shrinks away from the walls of the vessel containing it so that a vacuum gap forms between the product and the wall. This produces a condition of high but erratic thermal insulationto beset up between the mass of and the frozen product and the wall. Furthermore, as the volatile component was graduallylost from the mass the latter became more and more porous, filled with vacuoles, and became less and less conductant throughout. The older methods were content with warming the outer walls of the evacuated vessel containing the large frozen mass or relatively large frozen chunks of the frozen product. vSince the temperature at the wall could not be .maintained high for fear of damaging the product, and since the thermal conductivity was very poor, the heat actually flowed into the frozen mass very slowly. For example: somewhat over 600 calories are required to sublimate to dryness one gram of frozen blood plasma; the highest permissible temperature'of the walls is about .40 degrees C. In .sublimating the volume from a clinically useful volume of plasma, say 500 c. c., after .having frozen it in a slab, the thermal conductivity frequently .met with is so poor that 24-48 hours drying time is often required.

The thermal conductivity limitation is difficult to combat in older methods. With them the vapor cannot be produced as fast as it can be pumped away with a well constructed vapor pumping system. In all this discussion it is presupposed that adequate pumping has been provided or else this too will be a limitation. EX- perience with older methods has shown that it is easier to arrange for adequate pumping speed than to adequately provide a source of safe heat capable of rapidly freeing vapor from the frozen substance while keeping it frozen. One phase of the present invention concerns this latter problem mainly.

(2) Awkwardness and inefficiency result when the size and shape of the frozen mass being processed is not under suitable control. During the sublimation the rate of escape of vapor from a given substance depends upon two factors, (a) the temperature of the frozen product, (b) the area exposed to vacuum space. As explained above, heat flows very slowly into a large frozen porous mass. This usually results in the product becoming very cold and hence giving up its vapor slowly. Another equally bad situation can also occur. Sometimes large, solid slabs of frozen product become too warm locally at the points of contact with the warm walls of the container, resulting in melting at these points where the temperature is locally high and the escape of vapor is restricted. This local melting sometimes occurs notwithstanding the fact that the rest of the frozen product is still too cold to give off vapor rapidly. Furthermore, the large mass or large chunks offer very small area in proportion to their volume. Another disadvantage in freezing in bulk comes when an attempt is made to transfer the dried mass into another container. This is especially difficult when the transfer must be effected with absolute sterility. The large mass can generally be broken into chunks, but the chunks are irregularly shaped and do not pour well. The chunks are also not of the most desirable appearance. Grinding these chunks after dessication is awkward if sterility must be maintained.

(3) The older methods are not suitable for continuous production. Where it is desirable to continuously feed a liquid or semi-solid product through a single apparatus which takes it directly and continuously, to a suitable final dryness, the older methods are awkward. The invention permits this awkwardness to be overcome in a simple manner.

The desirable objects attained by the instant invention may be briefly set forth as follows.

The final volatile component is removed from the product while the latter is in the form of suitable, small, porous frozen particles of relatively uniform size and mass. The invention also includes a convenient, efficient, and rapid method for continuously and directly producing suitable frozen particles of liquid and semi-solid products, and of introducing these into the vacuum region where the final drying is made to take place. The method for producing and introducing frozen particles has other important advantages, including a means for almost instantaneously removing an initial fraction of the volatile component, and also a means for controlling and predetermining the fraction of volatile components lost before freezing sets in so as to produce a more suitable final product.

The following more detailed outline of the advantages of the instant process over older processes is of particular interest in reference to large scale production and commercial applicability of the process:

I. The drying time can be very greatly reduced. The conversion of liquid to dry solid can be done in one hour or less, whereas older methods require from ten to sixty hours for comparable quantities.

II. The product is superior.

A. The product desired, Whether granular, flaky, or in powder form, as well as the size and nature of the particles, can be prearranged and controlled. (NOTE-The 01d method generally requires the production of slabs or chunks which must later be broken up or ground if they are to be conveniently transferred into final storage bottles. The only alternative is to dry the product While the latter is already in the final bottle; this is very inefficient on a large scale although it may be practical on a small or moderate scale.)

( 1) The particles can be made so that they readily pour into final containers.

(2) The granules offer great area. Each granule is very porous due to the extremely rapid freezing method used, which might be termed explosive freezing. This makes the particles extremely soluble.

(3) The final product can be obtained in any degree of granulation without any grinding or meshing operations. A flaky, granular, or powder shape may be selected.

(4) The appearance of the particle form is better.

13. The volume occupied by the final product can be pre-determined and controlled. so as to obtain a more useful and convenient product. (Older methods generally produce a too bulky final product.)

(1) The final volume can be made smaller so that more product can be put in a given sized bottle.

C. The process is direct and rapid, and

can be made to operate at conditions less likely to damage delicate products.

(1) The freezing is done almost instantaneously without requiring any pre-conditioning of the liquid.

((1) Rapid freezing is known to be superior to slow freezing.

(1)) Preliminary degassing is not necessary.

55 1 i2) xflfherproductcan be: made toeothrouehthe com- :plete .idrying process in ..an.-: enclosed sterile' vacwuum. :It rcanxeasi ly abe ikept :sterile, and "the iifinalproductcan be re- :movedcsteril'ly .'(:a);The contamina- 1ti0n hazard is :cutfdo-wn. (b) The'rha-ndling is :at asminimum. 1(3) The yeryllomtemperature -:ca.n be maintained ithroughout the drying process although the drying is done :very rapidly.

D; verylowand uniform-water content :in the "final product can-be btamed.

(1) "The rate o'f loss o'f water accelerates with the degree of dryness. This isin contrast with old- --er processes where the final water comes ofi so slowly, that it'is inconvenient and impractical toremove'thelast traces.

There is less danger of melting the frozen product during its drying. III. The-process"can'easily be carried out continuously "Or' semi-continuously.

--A. Liquids or 'semi-solids can be converted' into batches of dried prod- -ncts.

BILiquid or-semi-solid products-canine continuously introduced into the drying apparatus while the dried product can-beremoved continuously-or *semi-rcontinuously from "the-apparatus: initsfinal container (or-ready. to put intoiinal con- 'tainers).

I. have experimentally determined thata' frozen product such as frozenplasma can be ,made .to 0

take 'up :heat -very rapidly, and made to lose its volatile component very-rapidly, if the product is in the form of. small frozenparticles, of relatively uniform size, Of porous andotherwise-suitable nature, .and :if rarnumber of .these :particles :are stirredontumbledundencertainconditionsrover a warmzsurface. ;.If the frozen :particlesare stirred over. a :warm:surfac.e or region while in ordinary atmospheric surroundings, :they take up heat so readily; .thatthey-melt. 'However, if thesefrozen particles :are stirred over ,.a warm surface while openly exposed :to .open' vacuum space fa-ispace where the .vapor 'evolved is removed sufliciently rapidlybynarapid-pumping system), then the particles can easily be kept below their melting point and still in acondition where they give 401T their xvaporzrapidly. iComplete dryness can :be easily andsafelyattained in less than one hour, in contrast withtheten-to sixty hours common with olderaprocesses.

Theex-pressions warmsurface or warm regiorf'isa relative one and is explainedasfollows. When-awell-insulated frozen particle containing a volatile'component such as wa-ter is exposed in vacuum, the initial'loss of vapor coolsthe particle bathed in more dense vapor.

6 untilthe-temperature of the particle becomes :so lowthatits-vapor escapesifrom its-surface just as :fast :as .it is pumped -completely: away. The temperaturewof :the' frozen particle can ithen'be .said to'be inequilibrium with the pumping speed of the pumpingsystemthe pumpin system including the immediate environment ,of-zthe particle itself .as well as exhaust pipes,.ilues, traps, .andaotualpumps. A well insulated particle exposed inxa high vacuum injgeneralzbecomes' verycold. However, this invention concerns the treatment of an aggregation'ofia-num- .ber of :particleaza group or-pile of them upzto several inches deep,'in such amanner aspto cause them to volatilize'rapidly. Obviously,aeach particle will momentarily take on a different equilibrium temperaturedepending upon its;state.:.of vacuum .exposure :and'of' thermal insulationfrom a source of heat. When, for example, ant-saggregate of particles stands .quietly-zat' the bottom era :hi-ghly evacuated (rapidly pumped) ":vessel, o-nly it-hose particles 'whiclrare fat the bottomof the pile infact onlythat portion of theseilatter particles which are ,in' actual contact 'withtthe surfaceof the bottom of:the vessel, takei'onthe temperature of the vessel. 'Ihe other particles are all better insulated and better exposedi'an-d become much colder than the vessel. Actual experience'with frozen particles of blood plasma, prepared-in a manner "to be described latch, has shown that a pile of porous, irregular-shaped particles is in actual, direct contact withithe walls of the containing vessel at onlya very few points. However, those particles at the bottom of the aggregate,- and in the neighborhood ofithe walls and bottom of the vessel, do Jhaveindirect thermal contact with the walls. This is because these particles are in'a region of relatively high vapor pressure (poorer vacuum due "to the blanketing effect of the upper layers of particles. The upper layers inhibit the easy escape of vapor to'suchan extent that the lower particles are This dense vapor conducts heat energy readily and acts; as -an indirect conveyance of the heat :of :the 'vessel walls to the irregular porous :surfacesmof the lower particles. This indirect conveyance. proves more efiective than that due to conductivity through the .few' available points of contact.

The foregoing :tends to interpret physically what is meant by a warm: surfaceiranda warm region. A warmsurface is one which has :a temperature higher than the. coldest particle in the aggregate. A warm regionis -a region where relatively good thermal contact :(directqor rindirect) canbe provided between "the particles and a sourceof heatsuch asa warmsurface or any other heat source, :suchas, ffor example, asinduced. high: frequency field of energy. Since some ofthe better exposed and insulatedrparticlestcan easily .bemade to takexon-very lowtemperatures, for example 50 C., a :suitable warm surface can be any temperature between -.50 C. and the highest that the productica ntsafely tolerate (40 C. for blood plasma).

I have experimentally foundthat anaggregate of suitable frozen particles can be safely heaped several inches deep :in the bottom of :arapidly exhausted vessel'whose walls and bottom arekept at a temperature far above the melting point of the product, Without danger of :melting :and coalescing the particles in such auvayasrtmspoil the-advantage .of their frozen state. Frozen particles, in contrast with large'slabs and irregular sizedxchunks of frozen m'ateriaLarei innoidanger of melting, regardless of the temperature of the vessel, as long as the vessel is provided with a sufliciently rapid exhaust system. Large chunks frequently melt where a large face is in good direct contact with a too warm surface and there is no easy path of escape of the locally formed vapor.

I have further discovered that when an aggregate, or pile, of suitable frozen particles are so stirred, tumbled, or otherwise agitated, that the relative positions of the individual particles are exchanged (all this being done in a vessel maintained in a highly exhausted condition and whose walls, bottom, or other surface or region, are maintained relatively warm and at least momentarily accessible to contact or proximity with the several particles), the aggregate then rapidly and efficiently gives up its volatile component so that it can be pumped away in the form of vapors and trapped gases. If the particles are of uniform size and the stirring is uni form, the particles dry uniformly throughout the aggregate. Large dense particles dry very much more slowly than small, porous ones whose surface is irregular and extended by corrugations, projections, and indentations. The particles must never be so cut off from exposure to the vacuum space that their vapor cannot escape fast enough to keep them cooled below freezing until the last of their volatile components has gone off and only their skeletons remain. For example, there must be no cavity into which the particles can fall and be so confined that their vapors cannot escape readily.

The particles should be so agitated that they are momentarily (as individuals or in aggregate) in a region of good thermal access but not entirely cut off from the pumping system and then transferred to a region of good vacuum exposure where their warmth permits them to emit vapor rapidly. A simple practical example is that of a pile of particles tumbled in a cylindrical tumbling drum which is maintained in a highly exhausted condition by means of a conventional vaporpumping system.

I further have discovered that if a liquid or semi-solid substance is exposed to a highly evacuated space suddenly, but in small volumes, these small volumes freeze explosively and suddenly. Small volumes of liquid may be quickly pushed into vacuum exposure or else a continuous stream or sheet of liquid may be projected into vacuum space. The rate and manner is so controlled that the liquid freezes as fast as it enters the region of good exposure. Further, if isolated and separate liquid volumes are exposed individual- 1y, separate frozen particles are formed. Also, if streams or sheets of liquid are so exposed that their explosive freezing, the expansion and contraction due to their rapid cooling and freezing, causes the ice to fracture, then too the result is a number of frozen particles. No grinding mechanism is necessary, although a mechanism for interrupting the continuous flow of liquid, and for directing and ejecting out of the way the resulting frozen particles, may be desirable.

The device for producing and introducing frozen particles, which forms a part of this invention, will be referred to as the injector, or injection device.

One purpose of the injection device is to offer a convenient and effective means for introducing liquid substances into a vacuum system in a form and condition suitable for further drying and processing. It has been found that subsequent drying and processing can be best carried out when the injection device produces and introduces a number of small frozen granular or flaky particles of a uniform size, each particle having a very irregular and porous surface (that is, each particle has a large area in proportion to its volume). The examples of injection devices hereinafter to be described are so designed as to accomplish this in an efficient and rapid manner.

A second purpose of the injection device is to freeze the liquid much more rapidly than is possible with older methods. Rapid freezing is high- 1y desirable in some products. The injection devices here described do this by exposing portions of the liquid suddenly to the open vacuum space, in such a way that evaporation takes place very rapidly and cooling and freezing are explosively sudden. When liquid is introduced into the vacuum in such a way that a large area in proportion to volume is exposed to the vacuum, the evaporation is very rapid, and hence the freezing is rapid. The injection devices described here cause the liquid to change to the frozen state in about one-tenth of a second, or less. No preliminary processing is necessary before the injection step. No preliminary de-gassing" of the liquid is necessary, nor any preliminary lowering of the temperature of the liquid. The liquid can be introduced at any convenient temperature and almost instantly converted to the frozen state. Furthermore, whereas older processes sometimes require the liquid to first super-cool before freezing takes place, the sudden introduction of liquid directly into the vaccum space is highly unfavorable to super-cooling. No delay in the freezing process due to super-cooling need be experienced with the instant process.

A third purpose of the injection device is to utilize, in a beneficial manner, the initial evaporation which causes the initial cooling and freezing (and cooling below freezing) to remove a portion of the water from the product. There is no novelty involved in freezing liquid by evaporation of vapor from its surface, and likewise there is no novelty in considering the vapor lost in this way an advantageous outcome of the auto-freezing process. However, with the instant method of injection, a greater quantity of vapor can be lost simultaneously with the freezing process, and this quantity can be predetermined and controlled at will so as to be most beneficial to the subsequent processing and to the final product. The rate of flow of liquid, the temperature of the temperature control jacket, the thermal conduc-' tivity of the material of the injection device, and the length of time the liquid and solid are caused to remain in contact with the internal and ex-" ternal surfaces of the injector (contact with a important advantage when products such as blood plasma are being processed. When such liquids are frozen and sublimated, the final bulk of the dried product is almost identical with that of the original frozen mass. The dried product can be conveniently pictured as the skeleton of the frozen mass, the volatile component having been removed without disturbing the original frozen shape. So if it is desired to have-the final bulk small, it is' better to haveonlya small liquid bulk at the moment of freezing. This srnallbulk is made possible easily with this injection freez ing method by controlling the above-mentioned factors so that a greatdeal of vaporhae already been lost before the product is frozen solid. Actual experiments have .shown that the final bulk can be reduced to less than half of-"that possible with the. older methods, ,without-damagingor de creasing the porosity or solubility. or usefulness of the product; Thispermitstwice as muchbf the product to be put in a-given storage and: dispensing bottle. Experience has. shown that the freezing speedisstill fast and'feifective although the vapor loss during freezing. .iscbntrolled. by

the above-mentioned factors-of course within certain limits.

The accompanying drawings are intended sole ly-for purposes of illustration and itis not-de siredrorintended to limit the-invention in any way, to theparticular forms-or devices'illu'strated;

norto any or allspecificdetails thereof, except i-ng asmay be defined in the appended claims:

Referring briefly to the-drawings; wherein various examples-of suitable apparatus for carrying out the invention and'attaining: the objects set forth above as well as other objects;. areshown, Figure 1- is a partly schematic longitudinal crosssectional elevation of an apparat-us'for vacuum drying of properly. exposed frozen particles which have been introduced into a drum I and are tum-'- bledbyrotation of the drum.

Figure2 is aview taken'on the line 2-2- of Figurel. V

Figure 3 is a cross-sectional-view'taken on the line 3--3 of Figure 1.

Figure l is apartly schematic crosssectional view. of an apparatus including one form= of-an injector through which liquid may be introduced and converted. in the receiving. chamber into frozen particles. V

Figure 5 is across-sectional view taken on the line 55of Figure 4.

Figure 6 is a cross-sectional viewtaken on the line 6-5=of'Figure -4:

Figure? is-aview similar to'Figureze, illustrating another form of injector. v FigureLSis a cross-sectional-view taken-on the line 8-8'of Figured 7 H Figure 9 is another view similar to Figure 4, illustrating still another form of injector:

Figure 10 is a cross-sectional 'view take'n on the line l0l0-of Figure '9. I

Figure 11- is a-partly schematic and partly longitudinal cross-sectional view of the rotating injector cylinders or rollersof Figure" 9, showing an electrical temperature :control 1 means for the rollers Figure 12' is a cross-sectional view of an apparatus for injecting theinflowingliquid into the,

cross-sectional viewof an apparatus forcarryin'g out the complete and. continuousprocess from the introduction of the liqu-idto the bottling;

of the: dried particles.

Figure 16 is 1 afragmentary view, similarr-to iii 10 Figure 4, but showing an injector adapted for introduction of a semi-solid such as meatto be frozen into particles.

Figure 17 is abottom plan view of the injector per se of Figure 15.

Figure 18 is a cross-sectional view taken on the line l8l 8 of Figure 19, showing a continuous flow'injector directed to a moving surface undergoing repeated distortion to freeor snap of"? frozen particles adhering thereto.

Figure19 is across-sectional elevational view, taken on the line I9--l9 of Figure 18.

Referring in detail to the drawings, and first to Figures 1, 2, and 3', the numeral 20 indicates the supports of a'frame on which is supported atrough 2| formed by the four walls 26a. Upright extensions 22 of the opposed end walls 20a have aligned openings therethrough to receive and provide bearings for the hubs 24 and 25 of a hollow airtight drum 23. The hubs 2d and 25 are partially conical, as shown, and have axial openings 24a and 25a, respectively, therethrough, and" are provided with suitable packings 26. A cone-shaped screen 23a. may be applied over the opening 24a, as shown. A pulley '21 on the hub is linked to adrive pulley 28 by a belt 29, and thus the drum 23 is rotated through a reduction gear box 38 by a motor 31. A supply of warm water, entering through the pipe 32, is passed or sprayed through the multipore nozzle 33 about both sides of the drum during rotation of the latter.

A conventional-mechanical air exhaust pump is shown at 3'1, driven by a motor or engine 35', leading'by a pipe 36 to a conventional vapor trap 31; A bacteria-proof filter 39 may be provided in the pipe 36. A pipe 40 extends into'the drum through thehub opening 24a and is joined to the vapor'trap pipe 38. Through the other hub opening 25a, an injector M, shown schematically, projects into the drum, to introduce into the drum in the manner hereinafter to be described, the frozen particles 42 of the liquid or semi-solid which it is desired to dry.

This device is a satisfactory example of rapid drying of the frozen particles 52i The vapor is continuously and rapidly removed through the pipe! and frozen in the trap 31, while warm water'flows over the surfaces of the drum. Owing, to the rotation of the drum, the granular' or fiakyparticles 42 of'frozen material are caused to" be agitated in that they tumble over the inner surface of'the drum and over one another. Theterm agitate wherever herein used, isintended to imply not only the tumbling just mentioned, but any other form of physical disturbance of the particles whereby their positions are open space between the particles, the vapor even here can escape rapidly enough to prevent melting,- as exemplified by the broken line path" 45; Region 46 is'the region'where the p'articles rea'ch maximum vacuum exposure and lose-vapor most rapidly.=

the above device'is'the satisfactory'method? of The essential feature illustrated in exchanging the positions of the particlesv 42' from the region to the region 45:

His to 'be noted that wherever water 'or a water jacket ismentioned herein, as a means Region 44- 1 1 for varying the temperature of any part, it is to be understood that any fluid other than water may be used.

Figures 4, 5, and 6 show an example of an injector, and the numeral 4'! indicates an airtight vessel with a connection 48 for a rapid exhaust system. The injector 49 comprises a cylindrical housin 50 projecting into the interior of the vessel 47. the housin and has at its open end a reduced nozzle 53. A channel 54 provides a passage between the outside of the housing 50 and the axial channel 52, and at the outside opening of the channel 54 an inlet pipe 55 is connected, through a valve 56, to the storage supply of liquid 5'! in a sealed container 58. The pressure of the inflowing liquid is controlled by the valves 56 and 50, the latter being connected in a pipe 60 leading from a high air pressure supply, now shown. A pressure gauge 6! is mounted in the pipe 55.

' A needle valve 62 is threadably engaged in the bore 52 and serves, in an obvious manner, to regulate the rate of continuous flow of the liquid out of the nozzle or orifice 53. A water jacket 63 is provided within the housing 50, having an inlet pipe 64 and an outlet pipe 65 communicating therewith through channels 64a and 65a, respectively. The orifice 53 and the face 66 of the injector are maintained at a desirable temperature,

as is obvious, by the water jacket in which a suitable fluid is circulated. As is also obvious,

the water jacket may be used to cool the inflowing liquid in the injector, instead of warmin it, if desired.

Rotatably mounted adjacent and axially parallel with the injector, is a shaft 6'! extending through the wall of the vessel and provided with a pinion 68 meshed by a drive pinion 69 driven by a motor 10. In the wiring diagram for the motor, a rheostat II is shown, whereby the speed of rotation of the shaft 61 may be regulated. A fan-like member 72 having one or more blades 13, is mounted on the end of the shaft 61, with the inner (right-hand) edges of the blades lying in the same vertical plane close against the face of the injector.

The cleaning off blades 13 are timed to such a rate of rotation, to permit a small amount of liquid to enter the vacuum space 5|, spread around the orifice, and freeze into a small puff or particle 14, before wiping the particle away from the face 66. ,The blades repeatedly remove these pufis as fast as they form, and the particles which thus fall are collected at the bottom of the vessel at 15, whence they may be removed by opening the trap door I6.

The form of injector 1'! shown in Figures 7 and 8 is provided with a multiplicity of orifices similar to the orifice 53 of Figures 4 and 5. Herein the liquid is ejected out of a hole, then the liquid flow is cut off and an interval of time elapses before the cleaning off blade reaches the frozen puff, which by then is frozen brittle and is easily removed without smearing.

For purposes of simplification, the same reference numerals are used on the vessel 41 of Figure 7 as above, to indicate parts which are identical, and the same is true of the water jacket in the injector H. The cylindrical housin 18 of the injector 11 has an internally beveled, or conical peripheral flange 19 projecting therefrom, and this flange is provided with a plurality of peripherally spaced holes 80. Through an axial bore 8| in the housing 18, a shaft 82 extends An axial opening 52 extends through rotatably, and a by-pass 83 extends from outside the housing to a diametrically enlarged portion 84 of the bore 8i. On its end the shaft 82 has a complementary frusto-conical plug 85 registering rotatably in the flange 19 but having its inner face 85 spaced from the face of the housing 78 at the base of the flange 19, to provide a pcripheral disc-shaped space 8? communicating with the bore 84. A single right-angled by-pass 88 extends through the plug 85 between the conical surface of the plug and the space 87, the opening of this by-pass in the conical surface of the plug being widened as shown at 89 and lying thesame transverse vertical plane as that of the peripheral flange holes 80. It is apparent that, as the plug 85 rotates on the shaft 82 within the flange 79, the opening 89 will align successively with each of the holes 80. A chain of gear 90, driven by a motor 9|, rotates the shaft 82. A speed control, not shown, similar to that shown in Figure 4, may be supplied for the motor 9| and for all other electric motors illustrated in the drawings. A wiper blade 92 is secured to the plug 85 and removes the frozen particle 14 which have formed about the openings 88. An advantage of this type of injector lies in that a great extension in speed is obtained because of the number of the holes 80, which may be in creased to any desired number.

The injector shown in Figures 9, 10, and 11 is a form in which the liquid is introduced for exposure in the vacuum in a plurality of continuous streams, although but one such stream may be provided, if desired, instead of a plurality. Herein the injector housing 02a has a pair of vertically spaced projections 93 extending into the chamber 5I, each having an axial bore 94 therethrough, and each bore 94 has a shaft 95 rotatable therein. On the ends of the shafts 95 are rigidly mounted rollers 96, spaced a greater or lesser distance apart. Between the rollers and behind a vertical plane through their axes, lies a horizontal pipe 91 having a plurality of holes 98 therethrough, facing toward the said plane. Wiper blade shafts 99 are pivotally mounted in suitable supports I00 and have blades IOI normally urged substantially tangentially against the rollers by springs I02. The liquid supply, not shown, enters through the pipe I03. A motor I04, through gears I05, rotates the rollers 96 in mutually opposite directions (in the directions of the arrows).

In this type of injector the streams of liquid I into the chamber 5| are exposed between the rollers 96 which are almost in mutual contact. The liquid adheres to the rollers, freezing as they carry it away. Actually, the freezing causes the liquid stream to break up into a number of isolated puffs. Some flakes adhere slightly and are knocked off when they reach the blades degrees beyond, and the blades free all puffs or particles which have not jumped off previously. No interrupting or pulsating means for the liquid flow is here necessary but may be provided if even more uniform size is desired in the frozen particles. The inflow of liquid as shown, is controlled by the valve I06.

It is to be noted that in all of the apparatus shown in the drawings, suitable air-tight stuffing boxes or other packing means is to be provided around all shafts or rotatable parts which extend from outside the vacuum vessel or receptacle to the inside vacuum space. Since the present invention is not concerned with any particular or new kind of packing or sealing means, all such means haveeither been illustrated in a conventional manner or have been entirely omitted.

In Figure 11 is illustrated a modification of Figure 9, showing a means for controlling the temperature of the rollers 95. Since the rollers may becomevery cold but are most effective at temperatures just below the freezing point of the liquid or semi-solid substance, some suitable means for control of their temperature may be desirable. Herein the rollers 95a are hollow, as are also their shafts 95a. In each roller a resistance or heat coil IEl'I, shown schematically, is mounted, and a two-conductorlead I58 leads therefrom through the hollow shaft 95a. By extendingthese shafts beyond their gears I55 and supplying them in a conventional manner with current-carrying slip rings I09 and connecting the leads' H of the conductor I58 thereto, a suitable electric current supply may be fed to the resistances [61. The wiring diagram of Figure 11 shows a rheostat III in series with the rings 0- and coils. I0! and an electric source. The temperature of the rollers, their speed, the speed of theliquid flowing in, can all be controlled,

and these factors determine the shape and size of the particles produced and their water content- In-Figures 12, Y13, and 14 isillustrated an apparatus. suitable for carrying out the complete process of freezing and drying, either as a continuous. operation, or first freezing and accumulatinga-mass of frozen particles and then drying them. Hereina vessel I I2, circular in crosssection, enclosing a vacuum space H3, has a suitable exhaust pump connection I I3 in the neck II4-of the vessel. A shaft II5 extends rotatably through the vessel andis adapted to be rotated by, any suitable means, not shown. A sleeve I I? is rigidon the shaft H5 and a pair of co-planar paddles or blades III, T-shaped in outline, extend. from thesleeve with their outer edges adapted to move close to the inner cylindrical surface H8 of the vessel. Spaces H9 are provided between the blades. A water jacket I30 partially encloses the vessel II8 to supply heat thereto, and a plug I3I permits of removal of the dried or partially dried particles.

Frozen particles I4 are introduced into the vessel through the injector I20, which may be of any desired type or form but which in Figures l2. and 13 is illustrated as embodying another type of wiper. The injector I2I otherwise may be. considered identical to that shown in Figures 4, 5, and 6, and such details thereof as are shown in Figures 12 and 13 are similarly numbered. The wiper comprises a blade I22 secured to a stem I23 extending pivotally through the cap I24 and having acoiled spring I 25 surroundingthe stem and anchored at one end to the bladeand at the other to the cap sleeve I25. A motor I21 drives a cam I25 against the surface of which an arm I29, rigid with the stem I23, is normally urged by the spring I25. It is obvious that rotation of the cam by the motor imparts an oscillating movement to the wiper blade I22 past the injector orifice 53.

The liquid source is introduced into the injector through theconnection 55 and upon emerging at the orifice 53 in the vacuum space II3-it freezes as described before, and the oscillating wiper repeatedly wipes off the adhering frozen particles from the face of the injector. Thestirring operation of the frozen particles I4 maybe carried on simultaneously with the injection operation, if desired, by simply rotating the shaft 5 simultaneously." The-accumulated particles are thus stirred'in such 'amanner asrnot to interfere with they easy and rapid-escape-of vapors and gases given ofi'by the particles.- The latter feature" applies also totheotherforms and means for stirring, tumbling. or moving; the frozen particles during. the drying" operation, which are set forth in the drawings: The blades H6 obviously move, stir, and. tumble the pai'ti cles 14' so that those particles which' are at one time insulated from the. warm surface (-the lower half of I- I 8-) are repeatedly. brought into thermal contact with, orin the neighborhood of,'..,the said surface, or region, which is capable of transferring. to: saidparticles: quantities of: heat from the warm waterinthe jacket I The movement of the particles in all. of the forms illustrated is done in every. case so; that the relative positions of the" particles isrepeatedly or continuously changedv so as to. exposethem part of the=time toopen vacuum (where they rapidly lose' vapor) and part of the time so' that they comeinto good thermal contactwith-the source of heat, where theypick-upheat;

In Figure. 15 is presented an apparatus for car.- ryingout a fully continuous-drying: process of a liquid on avery large. scale. This apparatusis capable of converting the. liquid productint-o an extremely dryv or partially dry-final product in a continuous fashion, then transferring this processed material into final containers as fast as it=is produced, and in such-a manner that the transfer is carried out withina closed sterile and evacuated space. The final containers can be sealed under sterileconditions and while-eitherevacuated or-filled with any desirable gas, such as nitrogen, for example.

The. method of introducing'into final containers and-sealing under-vacuum; ina continuous fashion, isdesirable in some cases where the product-would spoil if other than vacuum stored and would be in danger of contamination if transferred in open air. (blood plasma, for example). The continuous natureof the transfer of the dried particles is made possible by the pouring qualities of the small. particlesproduced by the instant process:-

A long cylinder l32'is-. provided with. amanifold I33 having communication therewith through the openings I34, and at the end I ofthe manifold a conventional large capacity very rapid vapor exhaust system, not shown, isattached. Screens I96may be mounted in the passagesv I34 and I42 to prevent escape of any very fine flaky particleswhich may be formed. A gate valve. I35 is adapted to close-the manifold at that end when desired, and a pressure gauge I36 is mounted adjacent thereto. A water jacket I3'I surrounds the cylinder I32 and is provided with an inlet I38 and an outlet I39. At the other endof the cylinder, a hood I40 is mounted on and encloses access both to the cylinder and to the manifold, the path from the hood to the former being shown atI4-I and tothe latter at I42. jects into the hood throughthe cap- I43 thereof.

of'the injector as well as its inlet and outlet, are

all similar to, and havetherefore been given the same reference numerals as; those shown in Figure 4. The injector shown in Figure 15, however, is of yet a different type, having the two orifices I which are adapted to open only when the single eccentric opening I45 through the disc I4! isaligned therewith, tov pfermitescapev of The injector I 44 pro"' The source of liquid supply: and its con nection with the injector, .and the water jacket the supply liquid into the hood, and the disc I41 is rotated on a shaft I48 by the motor I49 through reducing gears. The Wiper blade I95 is integral with the extension I48a of the shaft I48.

Frozen particles which leave the injector fall down the path I II into the cylinder I32. A shaft I50 extends through the cylinder I32 and is driven by the motor I5I through reducing gears I52. This shaft has rigid thereon a plurality of spaced blades or paddles I53. These paddles are alternately positioned at 180 degrees from each other, and they are provided with screw-twisted blades I54 (somewhat after the fashion of an airplane propeller), the direction of twist of the blades being such as to urge the particles 14 toward the exit I55 during rotation of the shaft I50. Thus, the latter rotation causes the paddles I53 to advance the particles (which have fallen down the path I4I to the bottom of the cylinder at the front end) step-by-step along the cylinder to the opposite or exit end. In addition, the paddles obviously spread some of the particles up the sides of the cylinder walls and in general stir all of the particles in the same manner as does the paddle II1 of Figures 12 and 13.

The cylinder I32 may be sloped downward toward the right to a greater or lesser degree to the horizontal, and the paddles and cylinder provide such configurations as to cause the particles to be stirred and tumbled up the walls of the cylinder and at the same time to move the particles, as just mentioned, in a slow progress toward the exit vent I55. The frozen particles progress along the cylinder at such a rate that they are sufficiently dry when they reach the vent I55. A cut-ofi disc I56, secured to and moved by a stem I51, permits the exit vent to be opened to permit dried particles to be ejected by gravity and the action of the stirring paddles, into a hopper I58. To permit airtight movement of the stem I51. a bellows I80 surrounds the same outside the device, in a conventional manner. The heat I59 of the hopper I58 is rtatably connected to the exit vent I55 so that the hopper may be tilted upward to a position at an angle in excess of 90 degrees to its normal substantially vertical position, as and for the purpose presently to be described. Means, not shown, may be provided to keep the disc I 56 open. A pressure gauge I6I is mounted, as shown, at the exit end of the cylinder, and thereadjacent is a pipe I62, with a valve I63, giving access to the cylinder. The pipe I62 branches into a steam inlet pipe I64 and a steam exhaust or vacuum pipe I65, both valved, by means of which the entire interior of the device may be sterilized with live steam under pressure and then exhausted, prior to use. The valve I66 permits of shutting the hopper outlet. A vapor gauge I61 on the hopper permits of checking the degree of dryness of the particles in the hopper.

A bottle filling chamber is shown at I68, into which the hopper outlet has communication through the opening I69; the valve I66 is closed except when the chamber I68 is also highly evacuated and a bottle I10 is in place within the chamber, beneath the hopper outlet. Branches HI and I12 of the pipe I13 leading from the chamber I68, lead to an exhaust pump and to a sterile gas supply, respectively. Valves I66, HI and I12 permit the chamber I68 to be used as an air lock for introducing empty bottles and removing full ones. The gauge I14 indicates the degree of vacuum in the chamber I68, and the pivoted door I16, provided with airti ht sealing means, not shown, permits new bottles to be hi troduced. The plunger I16 and its bellows I 11, similar to the bellows I60, permit filled bottles I10 to be pushed into position "011 where a suitable seal or stopper I18 can be placed in its neck by the bellows and plunger device I19. Once sealed, the bottle is removed from the chamber I88 after the valve I12 is opened and atmospheric pressure is established in the chamber. Thus the bottles may be sealed while exhausted or filled with any desired gas.

The apparatus of Figure 15 is illustrated simply as an example of a fully continuous processing and sealing into final containers under rapid and desirable conditions of sterility. Such an appartaus is capable of a relatively high processin rate. Large quantities of human blood plasma, for example, could be processed in a short time. A similar device six feet long has been calculated to dry several hundreds of litres of plasma daily. It is expected to completely process and. package the plasma in one hour. This capacity is several thousands of times that attained by conventional equipment of the same size.

It may be desirable to make the entire device tiltable in a vertical plane. Therefor any suitable means may be provided, such as the following. An ear I is provided on top of the manifold I33 and is pivotally suspended from a support I8 I. In order to give stability to the device in any tilted position, a pair of spaced jacks I82 are mounted under the device.

A possibility is that a quantity of particles which have entered the hopper I58 may be found to be insufficiently dry. Then, with the hopper outlet closed, the hopper may be swung upward about its rotatable union at the vent I55, and the apparatus may be tilted in a counter-clockwise direction, whence the particles in the hopper may be sent back into the cylinder for further drying.

Figure 16 is presented for the sole purpose of providing an example of an injector of introducing a semi-solid substance into the evacuated vessel 41. The injector I83 comprises a housing having a knife-edged worm I84, substantially similar to that of a common meat chopper or grinder, rotatable therein. A multi-orificed disc I85 closes the housing within the vacuum space 5I, and a wiper I86, similar in principle to those already described, is secured to the spindle of the worm. Meat or any other semi-solid substance fed into the hopper, not shown, of the injector I83 (and this may obviously be done under sealed and sterile conditions, if desired). is forced through the orifices of the injector, and upon emerging it will freeze explosively in the same manner as described in reference to liquids. The wiper will then, as before, wipe off the adhering particles of frozen material.

Another example of device for attaining the desired form and small size of frozen particles from the continuous stream injection of a liquid, is shown in Figures 18 and 19. A simple needlevalved injector is shown at I81, through the orifice 53 of which the infiowing liquid will pass. Mounted in front of this orifice is an endless belt I88 of suitable material, trained about spaced rollers I89. The rollers may be provided with sprocket teeth to register in corresponding sprocket slots in the edges of the belt to prevent slipping of the belt. A shaft I90, offset rearward of the plane through the axes of the rollers, extends down between the two sides of the belt L7 I88. and. has rigid thereon in, mutually spaced relationship, a pair of.dumbbc11-lik' e prongsflfl and I92, offset .QQdegrees fromeachotherjn a. horizontal direction. The shaft llBOQisYotatQd simultaneously with the rollersfltgl; but, are higher speed, by the chain. I93. For a portion of each rotation of the shaft 190, first .the u'pper member 19 and then the lower memes; 192' will spread the corresponding portion 'offthefadj'acent or rearward sideof the'bel't (at thd'top and bottom. respectively) thereby distorting and twisting the rearward surface of .thelbelt, The partially frozen liquid impinging onthe forward belt surface from the injectorwill further freeze and cling thereto, and while being carried around to the other side will have time to free'z ethoroughly. some of the material, which wtllcling to thebelt in the form of flakes, puffs, or small sheets, will, because of its brittle nature, he

e m d e i mel r i' ieleses hebeI rounds.

the o l r. t. wli terer me 1 re thebelt wi le snap ed, ef y. t, e.... mn1ns heeii distorting action of. the rnembers I94 and; 132 against therear side of .the belt, whence they i l e e bettemeithe essel- Her m warmi v el heet. .8 Such mean ou e e t i eet ne si tanees. such. a h wn in i ure fivemeans Qr. 1. Q11 f is shown in theform of a chain, I94, merely as an xam le. of. s ch m a sn a niee ers bove descri ed. an u tr d n e. dr wing th substance fed her eush ither ath nstre m in .suessive. ress. f ezes. e i1 iden1y..- n nt. ins he. c m pace ha .itrm shts etermed e i e e neso e. mal bitse he..ex qsi e y oz n drop rpray l on. in. radia directions frorn the orifioe. In. thos J'eGtQis proyidedwith wipers 'thedrop is giv @Il illterva of me eiere e nsw neelefi. n. which to lose a e ract o s; s in t al .mqist recenen h ..e m 1e 1 re z n (u t fiftyperent i sme s u e content by. theapeliceticn Q a-t to the in c or. asset o t .In...t. is

injectors in, wh ch hespray. st ikesa movin or distortable surface, this moisture loss du ipg em lete. eizns .qeeurse that urf c The ype r izelof theiro en particlesislargew etermined by hetyne of..the. stream (whether for removing clinging particles therefrom to'permit them to fall, as well. asfnodifibatidnsi of.the forms shown and described, "may'obviousl'y be provided, and the same applies 'to'the nfeansfor drying the frozen particles? Such changes-a ell as. refinements which may bring' the'pfocess to a higher degree of perfection 6r efficiency; an b1 made Without 'deb'alftih g flOlfi'"the" 'spirit' "arld sjcop'e of'the invention." M is to be'observedthat the presentirnprovecl device hasbee'fi'iid witl'hco'lls'ideiabl pr 1' V success. A feature of the invention *is'the an ifective' way or introducing" aflit'iili d "i freezing va'c'uufhiii such"a'fiia Whefitis desired? The} passes betweefi two ivol vifl v lib i 'i rit in the: dir is caused tob'e first' exp 7 v iii the region "where the cylindrr lfi sway iei'i ne. licits...

improvement n, the ap arat m r m pro- .25 m ans not h wn ay. also. e. r v ed o 18 fits .e ese to the evc ri e ums nd sets to prevent excessive'exposurelof ithe liquidat the orifices' 98.. The liquid does not freeze until it passes betvleen the drums arid emerges *on the other side wherejit freezes in contact only with surfaces .atii't tmay be' sed i the a of om pro s.

I a m rove .flhm e n y ipe '91 is a with amo or; s an ular cross ct n so a tomore perfectly fill the gap between the rollers onthe sid'e. where thefrolle'r surfaces are moyili toward one another. Another important yidipg'a means for controlling the temperature of the entry pi ,.91 so} thatfreezing does not occur at'or within the orifices 98; especially at the startof .flo'w ofliquid and before equilibrium conditions have been reached. A satisfactory method of controlling the temperature of pipe 9'! is to jacket this pipe andv circulate liquid through this jacket at controlled. temperature from ather'mostatic circulating system. Circulating an antifreeze is most reliable although ordinary tap water maybe circulated rapidly w t a most as se d e lts- One improved form'oflthe device wasprovided with hollow shafts (9541). through which liquid couldbeIcirculatedinfand out ofeac'h drum at entrolle tempera u In s Way; t e mperatureof thedrumsurfaces can be controlled oyera wide range. By use ofan antifreeze circulent, drum temperatures somewhat below freezingcould. be permitted, and. this situation was foundbeneficial whe'n such'thingslas' citrus juices were frozen for subsequent freeze drying. By reducingthe temperature of the drums as far as possible. the loss of .moisture prior to the freezing was minimized and the production of a nonfreezingsyrup film on the frozen flakes was minimi pl. in this parti u a ly. difficult yp o s stance.

It is likewise to be o lgseryed thatthe present ni t en o ides. auni uem h d iha si reezerd ied ma rial wh h s il u tra ch me'ti e i ie- 15 an which as v d o e a. va uable. cont buti n to th rt. Extensive tests with a par tus imi r o hat o ie- 15 avejbeei s ew th n me ous .i e eried reducts,v The merits ofthe noyelsystem include the l 'ovzins 1. 'The, 1net hod permitsiullest protection and Preservation of the; desirable characteristics of de ieate. r ez;e; r ed eria '12.: ftperrnits e use eff a o t an term. f e ntaijne, cially'cheapercontainers 'The containerne'ednot' be an itationupon the drying o eration. s s. he eesefli jnresei .pract e 0f insert:

3. harge s cale andfullyautomaticfreeze dryiii ertakejnwith ma eri is Free e-d ie m als.arer si a lyjd fiere freinerdinsry stancesjandj because of their 'unique nature require special precautions in storage. Freeze-drying produces substances which are extremely porous and present a vast surface area far exceeding that of ordinary dried substances. Because of this area, freeze dried substances are unusually reactive to gases, vapors and contaminants. In addition, freeze drying is generally applied to the more sensitive substances where efforts are made to preserve delicate factors such as flavors or biologically active factors.

In most cases it has been found that freezedried material can be preserved satisfactorily only in sterile atmospheres or under vacuum and by exclusion of undesirable chemical and biological contaminations. It has frequently been found so difficult to avoid contamination of the final product that the cumbersome (and unnecessary) procedure has been resorted to in which the entire drying operation is carried out Within the final container and the material is then sealed in this container without its ever being removed. This primitive method not only restricts the choice of containers, but causes a serious limitation to the drying rate. In contrast, the instant invention provides equal protection to the final product but allows more convenience, control, and economy.

At the end of any freeze-drying operation the desiccated substance is under a high vacuum within the drying chamber. In order to be useful this material must be dispensed into containers resisting the deleterious effects of the surroundings in which storage is to take place. It is not generally realized that a transfer of the dried material in the open air causes the absorption of oxygen and humidity and other contaminations which cannot be eliminated by reexhausting the material in a new container. Transfer must be done only in a closed system where all contact with contaminants is avoided.

Furthermore, my invention provides a method and apparatus which permit the removal of desiccated material from any freeze-drying member which is maintained at high vacuum at all times. An air-locking device is provided which excludes contamination during the transfer, filling, and sealing operations and permits only the desired atmosphere to come in contact With the substance.

It should be understood that in many cases it is economical and advisable to use a rigid container and seal under vacuum. In such instances glass ampules or bottles or metal containers can be used. In other instances, the desired container (such as large tin cans, for example) will withstand only a moderate vacuum without collapsing. In still other instances, such as in the case where flexible packages are used, the package is most suitably filled at a pressure approximating that of the outside atmosphere, or else slightly lower or higher. The present invention provides means for meeting all these contingencies while affording the maximum protection to the freeze-dried product.

A salient feature of the instant invention is the step of transferring the desiccated material.

out of the processing chamber into an air-locking chamber which may be alternately exhausted (by an external pumping system) to a vacuum approximating that maintained in the drying chamber, and then may be flooded with an desired gas at controlled pressure (from the highest vacuum to slightly above atmospheric pressure). Of

course, in the special case where the container is to be filled under vacuum no gas flooding is done.

In an elementary form of apparatus illustrated in Fig. 15, air lock chamber .58, valve lfiii, communicating to the high vacuum space of the dryer, and valves Ill and I12 which lead to the pump and gas supply, respectively, are provided.

The air-tight door 15 leading to the atmosphere is also an essential part to all modifications of the invention. The bottle H6 is merely an ample of one form of container which can be The sealing device I19 as well as the contain-er conveying device l1! and the filling spout as well as the general confi uration of the chamber are all subject to such modification as is w known in the art so that any other suitable pa age may be filled and sealed. For example, hen the bottle H0 is substituted by a tin can the ing device I79 is replaced by the conventional can sealing device well known to those skiled in the art.

In the arrangement illustrated in Fig. 15, the dried material is admitted directly into the con tainer I70 (while the chamber I68 is exhausted), and then any desired gas is admitted to the chamber I68 (after valve I66 is closed). It is obvious that this cycle can be modified, for convenience in certain circumstances, so that the dried material is first introduced into the air lock, then flooded with gas, and finally portioned into the containers and sealed therein. A suitable storage hopper with the air lock chamber would then be required as well as obvious modifications of the dispensing and sealing devices.

In a further obvious modification for that par ticular case where the final package is to be sealed at approximately atmospheric pressure, the dried material need not be filled into containers within the air locking chamber, but rather may be removed from the air look (after having been flooded with the desired gas at about atmospheric pressure while within the air lock) and be packaged and sealed in another device where the desired atmosphere is maintained.

It should be noted that common to the above modifications, and responsible for their success. is that step of flooding the porous material while within the air lock with the gas used in packagmg.

Most freeze-dried substances are hygroscopic. that is they will pick up moisture from ordinary atmosphere. This they do very quickly because of the immense area they present. Experience has shown that storage is best at very low moisture content. As a rule a moisture content of approximately one percent 1%) (or between .'7% and 2.0%) is adequate to preserve most foods and many biologicals. It is important that any gas admitted into the final package does not increase the moisture content appreciably by virtue of its humidity. The filling gas can be considered safely dry if it will not increase the moisture by more than about 1 6% of the dry weight (that is .03% to 0.3%). Commercial gases such as nitrogen are usually suitable, but, for safetys sake, should be passed through a drying agent until it is certain they will contribute nothing appreciable to the moisture content of the desiccated product.

Because of its high percentage of oxygen, ordinary air is not most satisfactory for filling packages of most freeze-dried products, even foods. For example, freeze-dried coffee extract absorbs considerable amounts of air within a few minutes and reacts with it with detriment to its flavor. The present invention provides a suitable means for excluding air while permitting storage under vacuum or a more suitable gas.

One device similar to that shown in: Fig; 15 was successfully used to-carry out hundreds of packagingoperations, In this-instance, freeze-dried citrus juiceswere-removed from the drying device andsealed into ordinary tin cans both under vacuum and underseveral inert gases. Besides having obvious modifications for application to tin cans the apparatus had certain im provements not shown in Fig. 15.

Rather than having the dried material fall by gravity into the air lock chamber, the material was'progressed in a positive manner into this chamber by means of a mechanical conveyor (or the shake-table type). In addition, the closeable portal between the high vacuum dryer and the air lock chamber (represented by gate valve H56 in Fig. 15) was made of large diameter and was arranged so the materials conveyor could be projected through this portal while the latter was open. Inthis way, the material was con-v veyed through theportal without the dried material ever coming in contact with the sealing seats. The conveyor was withdrawn from the portal before the latter was reclosed. In this manner, the portal could always be closed absolutely tight without danger of dried particles presenting effective closure.

Although the present invention has been described in conjunction with certain preferred embodiments, it is to be understood that modi-.

fications and variations thereof may be resorted to without departing from the spirit and scope of the invention, as those skilled in the art will readily understand. Such variations and modifications are to be considered within the purview of the application and thescope of the appended claims.

I claim:

1. The improved continuous method of processing in a high vacuum, freeze-drying chamber freeze-dried material constituted of explosively frozen solid particles which are extremely porous with'a vast surface area far exceeding ordinary dried substances and which are unusually sensitive to contamination by the atmosphere, sealing the freeze-dried material intocontainers under selected and controlled conditions including a high vacuum, and air-loc'xing the freeze-dried material outof the vacuuminto the atmosphere which comprises continuously introducing material other than substantially wholly volatile matter including masses containing at least one liquid and at least one solid in a sub-divided form into a high vacuum, freeze-drying chamber, continuously subjecting said material in said freezeis drying chamber to a vacuum so extremely high as to provide an extremely low vapor pressure of water to explosively freeze said material into porous solid particles, continuously progressing said explosively frozen material through said freeze-drying chamber under said extremely high vacuum until said material is freeze-dried into solid particles with extreme porosity and with a vast surface area far exceeding ordinary dried substances, continuously discharging said solid freeze-dried material from said freeze-drying chamber without coming into contact with the atmosphere, continuously collecting said discharged material in a storage hopper maintained under a vacuum from the said high vacuum prevailing in said freeze-drying chamber, continuously maintaining said vacuum in said storage hopper, intermittently connecting said hopper with a filling chamber containing a container while under a high vacuum approximating that 1 idrl lipfi r fll ns nd ealin i -99 with; said porous particles of freeze-dried material without containinationby the atmosphere, irookin said sealed c n ain rm s i fi .ing chambeng and thereupon transferring said dried substances and which are unusually sensitive Ito-contamination by the atmosphere, sealingthe freeze-dried material into containers under-selected and controlled conditions including a high vacuum, and'air-locking the freeze-dried material out of the vacuum into the atmosphere which comprises continuously introducing. material other-than substantially wholly volatile matter including masses containing at least one liquid and at least one solid-in a sub-divided form into a-high vacuum, freeze-drying chambenconti-nuously subjectingsaid material in said freezedrying-chamber to va-vacuum .so extremely high as-to provide .an extremely low vapor pressure of water to explosively freeze said material into porous solid particles continuously moving said explosivelyfrozen material mechanically over a heated surface in said freeze-drying chamber undersaid extremely high vacuum until said material is freeze-dried into solid particles with extreme porosity and-with a vast surface area far exceeding ordinary dried substances, continuously supplying heat tosaid heated surface, continuously discharging said solid freeze-dried material from said freeze-drying chamber without coming into contact with the atmosphere, continuously collecting said discharged material in a storage hopper maintained under a vacuum from the said high vacuum prevailing in said freeze-drying chamber, continuously maintaining said vacuum in said storage hopper, intermittently connecting said hopper with a filling chamber containing a container while under a high vacuum approximating that in said hopper, filling and sealing said container withsaid porous particles of freeze-dried material without contamination by the atmosphere. air-locking said sealed container from said filling chamber, and thereupon transferring said sealed container filled with said porous particles of freeze-dried material from said filling chamber to the atmosphere while continuing the aforesaid continuous operations.

3. The improved continuous method of processing in a high vacuum, freeze-drying chamber freeze-dried material constituted of explosively frozen solid particles which are extremely porous with a vast surface area far exceeding ordinary dried substances and which are unusually sensitive to contamination by the atmosphere, sealing the freeze-dried material into containers under selected and controlled conditions including a high vacuum, and air-locking the freeze-dried material out of the vacuum into the atmosphere which comprises continuously introducing material other than substantially wholly volatile matter including masses containing at least one liquid and at least one solid in a sub-divided form into a high vacuum, freeze-drying chamber, continuously subjecting said material in said freezedrying chamber to a vacuum so extremely high as to provide an extremely low vapor pressure of water to explosively freeze said material into porous solid particles, continuously progressing said explosively frozen material through said freeze-drying chamber under said extremely high vacuum until said material is freeze-dried into solid particles with extreme porosity and with a vast surface area far exceeding ordinary dried substances, continuously discharging said solid freeze-dried material from said freeze-drying chamber without coming into contact with the atmosphere, continuously collecting said discharged material in a storage hopper maintained under a vacuum from the said high vacuum prevailing in said freeze-drying chamber, continuously maintaining said vacuum in said storage hopper, checking the degree of dryness of said particles in said hopper, returning particles not having the desired dryness to said freeze-drying chamber for further drying, intermittently connecting said hopper with a filling chamber containing a container while under a high vacuum approximating that in said hopper, filling and sealing said container with said porous particles of freeze-dried material without contamination by the atmosphere, air-locking said sealed contain'er from said filling chamber, and thereupon transferring said sealed container filled with said porous particles of freeze-dried material from said filling chamber to the atmosphere while continuing the aforesaid continuous operations.

4. The improved continuous method of processing in a high vacuum, freeze-drying chamber freeze-dried material constituted of explosively frozen solid particles which are extremely porous with a vast surface area far exceeding ordinary dried substances and which are unusually sensitive to contamination by the atmosphere, sealing the freeze-dried material into containers under selected and controlled conditions including a high vacuum, and air-locking the freez-dried maliquid and at least one solid in a sub-divided form into a high vacuum, freeze-drying chamber, continuously subjecting said material in said freeze-drying chamber to a vacuum so extremely high as to provide an extremely low vapor pressure of water to explosively freeze said material i into porous solid particles, continuously progressing said explosively frozen material through said freeze-drying chamber under said extremely high vacuum until said material is freeze-dried into solid particles with extreme porosity and with a vast surface area far exceeding ordinary dried substances, continuously discharging said solid freeze-dried material from said freeze-drying chamber Without coming into contact with the atmosphere, continuously collecting said discharged material in a storage hopper maintained under a vacuum from the said high vacuum. prevailing in said freeze-drying chamber, continuously maintaining said vacuum in said storage hopper, intermittently connecting said hopper with a filling chamber containing a container while under a high vacuum approximating that in said hopper, admitting sterile gas into filling chamber and container therein, filling said container in the presence of said steri e with said porous particles freeze-dried material, sealing said container filled. with said freeze-dried material and said sterile gas Without conta1nination by the atmosphere, air-locking said sealed container from said filling chamber, and thereupon transferring said sealed container filled with said porous particles of freeze-dried material from said filling chamber to the atmosphere while continuing the aforesaid continuous operations.

THEODORE R. FGLSOM.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 1,884,429 Warner Oct. 25, 1932 1,911,125 Miller May 23, 1933 2,047,935 Beal et al July 21, 1936 2,078,933 Dean et a1 May 4, 1937 2,079,514 Leetz May 4, 1937 2,100,151 Tietz Nov. 23, 1937 2,138,356 Ryan et al Nov. 9, 1938 2,151,100 Hadley Mar. 21, 1939 2,248,365 Leonard July 8, 1941 2,268,289 Kronquist Dec. 10, 1941 2,380,339 Siedentopf July 10, 1945 2,389,452 Patterson Nov. 20, 1945 2,411,152 Folsom Nov. 19, 1946 2,471,035 Hurd May 24, 1949 

